Godiva World Series User manual

World Series Pump with Integrated
SmartCAFS 200
Installation and Operation Manual
GODIVA LTD
A Unit of IDEX Corporation
Charles St
Warwick CV34 5LR
England
[phone]
[phone]
www.godiva.co.uk
[e-mail]

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GP/252
Issue 3, April 2012

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
AMENDMENT RECORD
Model: SmartCAFS200 Manual
Mod
Date
Page/s
Amendment
New Issue
No.
1
July 2006
All
New Issue
Issue 1,
2
September
2008
20
New diagram/photograph for air injection point
Issue 2
3
April 2012
9
Gearbox oil capacity – now 1.2 litres
Issue 3

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
AMENDMENT RECORD............................................................................................ 2
INTRODUCTION........................................................................................................ 5
IMPORTANT NOTES................................................................................................. 5
SAFETY - RELEVANT DATA.................................................................................... 6
MAINTENANCE........................................................................................................... 6
TRAINING.................................................................................................................. 6
SAFETY POINTS......................................................................................................... 6
NOISE....................................................................................................................... 6
ENVIRONMENTAL PROTECTION............................................................................ 7
GENERAL DATA....................................................................................................... 8
COMPRESSOR........................................................................................................... 8
COOLING SYSTEM ..................................................................................................... 8
FOAM PROPORTIONING SYSTEM 3.3 &5.0 -CLASS AAND BFOAM COMPATIBLE............ 8
DIRECTION OF ROTATION -GEARBOX INPUT FLANGE.................................................... 8
LUBRICANTS ............................................................................................................ 9
COMPRESSOR........................................................................................................... 9
PUMP GEARBOX........................................................................................................ 9
PUMP BEARING HOUSING........................................................................................... 9
MODEL IDENTIFICATION SYSTEM................................................................................. 9
RECOMMENDED FOAM AGENTS ......................................................................... 10
FOAMLOGIX 3.3/5.0 COMPONENT GROUP................................................................. 11
SYSTEM OVERVIEW .............................................................................................. 12
COMPRESSOR......................................................................................................... 12
OIL COOLER ........................................................................................................... 12
SEPARATOR TANK................................................................................................... 12
MANIFOLD............................................................................................................... 13
FOAMLOGIX ............................................................................................................ 13
OIL FILLING POINTS................................................................................................. 14
BEARING HOUSING .................................................................................................. 14
GEARBOX ............................................................................................................... 14
GEARBOX IN DOWN POSITION................................................................................... 14
GEARBOX IN HORIZONTAL POSITION,LEFT OR RIGHT OF PUMP ................................... 15
SEPARATOR TANK/COMPRESSOR ............................................................................. 16
COMPRESSOR DRIVE BELT....................................................................................... 17
FOAM TANK LOW LEVEL SENSOR.............................................................................. 18
ADDITIONAL INSTALLATION POINTS ........................................................................... 18
BY-PASS VALVE...................................................................................................... 20
ELECTRICAL WIRING CONNECTIONS................................................................. 21
VEHICLE DESIGN CONSIDERATIONS.................................................................. 22
INSTALLATION AND INITIAL SET-UP FOAMLOGIX. ........................................... 23
OPERATION............................................................................................................ 23

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
FOAMLOGIX CONTROL PANEL FUNCTIONS................................................................. 23
COMMISSIONING /START-UP PROCEDURE ................................................................ 23
CALIBRATION OF FOAMLOGIX ................................................................................... 24
OPERATING THE WT_CWS_C FROM A VEHICLE WATER SOURCE.............................. 27
FOAMLOGIX CONTROL PANEL .................................................................................. 27
ENGAGING PTO &PRIMING MAIN PUMP ................................................................... 27
DISCHARGING FOAM AGENT ONLY............................................................................ 28
DISCHARGING CAFS............................................................................................... 28
WET FOAM OR DRY FOAM........................................................................................ 28
SHUTTING DOWN..................................................................................................... 29
1. TURN OFF COMPRESSOR................................................................................... 29
OVERHEAT SHUT DOWN........................................................................................... 29
MAINTENANCE SCHEDULE WT(S)_C................................................................... 30
QUARTERLY............................................................................................................ 30
ANNUALLY OR EVERY 200 HOURS ............................................................................ 30
ANNUALLY OR EVERY 400 HOURS ............................................................................. 30
BI ANNUALLY .......................................................................................................... 30
MAINTENANCE SCHEDULE FOAMLOGIX............................................................ 30
AFTER EACH USE.................................................................................................... 30
ANNUALLY .............................................................................................................. 30
BI ANNUALLY........................................................................................................... 30
MAINTENANCE OPERATIONS COMPRESSOR.................................................... 31
COMPRESSOR OIL LEVEL CHECK -OIL /FILTER CHANGE............................................ 31
COMPRESSOR AIR FILTER........................................................................................ 31
COMPRESSOR OIL SEPARATOR ELEMENT.................................................................. 31
COMPRESSOR DRIVE BELT....................................................................................... 31
MAINTENANCE OPERATIONS FOAMLOGIX........................................................ 31
STRAINER -FOAM.................................................................................................... 31
CALIBRATION .......................................................................................................... 31
FAULT FINDING...................................................................................................... 32

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
INTRODUCTION
This manual contains information relevant to Godiva single or multi-pressure World
Series Pumps, when partnered with Compressed Air Foam Systems (CAFS)
FoamLogix Models 3.3,5.0 & 6.5. Other than performance, foam capability and
installation of the FoamLogix units, the Godiva components are common.
IMPORTANT NOTES
Please read this manual before operating the pump.
CRITICAL: The pump Bearing Housing, Gearbox and Compressor are NOT filled
with oil ex works. Refer to section Installation and Set-up (Oil Filling Points) before
operation.
Correct lubrication and maintenance is essential if satisfactory performance is to be
maintained.
Do not run the pump without water in the pump casing.
The terms ‘Left Hand’ (LH) and ‘Right Hand’ (RH) apply when the pump unit is
viewed from the suction tube end; for the purposes of this document, this is regarded
as the front of the assembly.
!

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
SAFETY - RELEVANT DATA
Thank you for purchasing a Godiva Pump.
Godiva Pumps are designed to give safe and reliable service. BEFORE use
however, it is essential that the Operating and Installation Instructions are
carefully read and understood.
Maintenance
It is the responsibility of the user to ensure that the equipment is maintained in a safe
operational condition. Local legislative conditions may apply. UK only, Maintenance
(Regulation 5) of the Provision and Use of Work Equipment Regulations 1998
applies.
Training
It is ESSENTIAL that Godiva pumps are operated ONLY by TRAINED PERSONNEL.
Please contact Hale Products Europe Ltd to discuss your training needs.
Follow the operating procedures laid down in this document and avoid personal
injury.
Safety Points
The following points apply to pumps driven by petrol, diesel or other means:
DO NOT OPERATE the unit close to flammable materials or structures.
DO NOT SMOKE while operating the unit.
DO NOT inhale fumes or gases.
Avoid prolonged skin contact with fluids, particularly if corrosive or
carcinogenic.
When in use, keep ALL UNTRAINED people AWAY from the unit.
Where appropriate, eye protection should be worn.
Isolate the electrical supply when working on the pump.
Batteries produce EXPLOSIVE GASES, do not expose to sources of heat and
naked flames.
DO NOT lift heavy weights without assistance.
DO NOT remove protective guards or shields.
Noise
Operators must wear suitable EAR PROTECTION when the pump is running.

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
ENVIRONMENTAL PROTECTION
It is prohibited to pour engine oil and other contaminants onto the ground, down
sewers, drains, or into water courses.
Dispose of lubricants through authorised waste disposal contractors, licensed waste
disposal sites, or to the waste reclamation trade.
If in doubt, contact your Local Environmental Agency for advice regarding disposal
policies.

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
GENERAL DATA
Compressor
Model Enduro 12
Maximum Operating Speed 6500 rev / min
Nominal speed of operation 5000 rev / min
Nominal power consumption 40.0kW
Direction of rotation Anti-clockwise (viewed on pulley)
Cooling System
Type Oil / Water Shell & tube type
Cooling water flow-rate 50 Litres / Min at 7.0 Bar
Foam Proportioning System 3.3, 5.0, 6.5 - Class A and B Foam Compatible
Manufacturer Hale Products Inc
Model FoamLogix 3.3 / 5.0 / 6.5
Type Electronic foam proportioning system
Operating voltage 12 and 24 volt systems available
Fuse rating 12V / 24V 60 / 40 amp
Current draw (Operating) 12V / 24V 30 / 24 amp
Current draw (Max) 12V / 24V 60 / 30 amp
Wire size 12V / 24V Minimum 8.5mm2
Max. Foam Agent Flow rate 3.3 = 12 l/min
5.0 = 19 l/min
6.5 = 25 l/min
Direction of Rotation - Gearbox Input Flange
Clockwise only - viewed on gearbox input drive flange

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
LUBRICANTS
Compressor Recommended: Screw compressor oil in
compliance with ISO Viscosity grade 32 to
46.
Alternative: SAE 10W/40 automotive
multigrade oil.
Capacity TBA
Pump Gearbox (Capacity 1.2 litres approximately)
Recommended:BP Energol GR XP 68 or
similar
Pump Bearing Housing (Capacity 0.75 litres approximately).
Recommended:10W/40 or 15W/40 Multi-
grade engine oil.
Model Identification System
Variations of the World Series pump with CAFS are identified thus:
W T A C
T = twin pressure: S = single pressure
A = aluminium B = bronze
Compressed air foam
World Series Pump

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
RECOMMENDED FOAM AGENTS
Hale FoamLogix Models 2.1A and 3.3 approved Foam compatibility list.
Type of Foam
Concentrate
Manufacturer
Brand Name
CLASS A FOAM
US Forestry
Service
Approved
ANSUL
Silvex Class A Foam Concentrate
Angus
Forexpan S (0.1%-1.0%)
Chubb National Foam
1st Defense Class A Cold water
Foam
Chubb National Foam
Knock-Down
Monsanto
PhosCheck WD881
Chemonics
Fire-Trol Fire Foam 103
Chemonics
Fire-Trol Fire Foam 104
3M
Light Water FT-1150
Non U.S.
Forestry Service
Approved
ChemGuard
Class A Plus
Unifoam Co. Ltd.
UniA 1%
3M
Light Water SFFF
CLASS B FOAM
AFFF- Alcohol
Resistant
Concentrates
3M
3% Alcohol Type AFFF Conc. (P/N
98-0211-6573-7)
Ansul
3x3 Low Viscosity Alcohol Resistant
Concentrate
ChemGuard
AR 3%-6% Part # CAR36P
ChemGuard
Ultraguard 1%-3% Part # C-133
Angus
ALCHOSEAL 3.3%
Chubb National Foam
Universal Gold 3% AR-AFFF
Chubb National Foam
Universal Gold 1% - 3% AR-AFFF
US Foam
1-3% Alcohol Resistant AFFF (P/N
US-AR13)
AFFF
Chubb National Foam
1% Aero-Water
SPECIALTY FOAM CONCENTRATES
Protein
Chubb National Foam
Terra Foam 3% CF
Chemonics
Durra Foam 3%
FIRE FIGHTING WATER ADDITIVE
Hazard Control Tech.
F-500 (1%, 3%, 6%)
The above foam concentrates have been tested by Hale Products to ensure
compatibility with FoamLogix models 2.1A and 3.3. This information is intended to
assist the end user in selecting compatible foam concentrate(s) but is not a
determination of fire fighting efficacy. Always consult local application and
environmental regulations before selecting a foam concentrate and refer to the
FoamLogix user manual for additional information.
Note: Valid from September 2005. Please contact your Hale representative if your
foam is not listed.

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
FoamLogix 3.3/5.0 Component Group
FoamLogix
Pump
Dual Tank
Selector
Literature
Pack
Dual Tank
Extension
Harness
In-Line
Filter /
Valve
Assembly
Link
Harness
Dual Tank
Instruction
Plate
Vehicle
Interface
Harness

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
SYSTEM OVERVIEW
The WT_C or WS_C is a Compressed Air Foam System comprising of five major
components – Air compressor, FoamLogix (foam proportioning unit) CAFS Manifold
(foam mixing and control system), Oil-water heat exchanger & Separator tank
A metered amount of foam is introduced into the Manifold and mixed with water from
the pump discharge manifold. The foam and water blend is then fed to a control valve
(ARC) where wet or dry foam may be selected (air ratio control section of manifold).
Compressed air is then injected and the resulting foam / water / air combination is
completely mixed by the X-mixers during discharge.
Safety interlocks are provided to ensure that:
1. Foam cannot be introduced unless water is flowing through the unit.
2. ‘Slugging’ (unmixed air and water) in the discharge line) is prevented. Air
cannot be injected in the absence of foam and water.
3. Air injection when the foam tank is empty is prevented. Foam tank low level
switches are provided and MUST be fitted.
Compressor
The rotary twin-screw compressor is rated at 200 SCFM @ 10 bar and is driven by a
toothed belt. The compressor is engaged, or disengaged from the pump drive, via an
electro-magnetic clutch.
Oil Cooler
Compressor lubricating oil is cooled by water taken from the main pump, via the
water supply line; cooling water being supplied from pump delivery and returned to
pump suction. The compressor will reject up to. 40.0 kW of heat energy to cooling.
The installer must consider this additional thermal load.
When the compressor is stationary, residual system pressure is vented by a blow-
down valve.
NOTE: The compressor should not be run without cooling water.
Separator Tank
The separator tank holds the oil required for lubricating the compressor and
separates the oil from the oil/air mix discharged from the compressor. The separator
tank also has a minimum pressure valve that ensures that air pressure is maintained
above 3 bars to maintain correct lubrication.

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
Manifold
The manifold incorporates an air ratio control valve through which degrees of wet or
dry foam mixture can be selected. Compressed air is then injected and the resulting
foam / water / air combination is thoroughly mixed by the X-mixers during discharge.
A By-pass valve is fitted to help obtain the required dry foam flow rate, this valve is
adjusted and set during the installation stage, it is not required during normal
operation.
CAFS units are best suited for use with Fresh Water.
For salt water compatible foams, seek advice from the foam agent manufacturers.
FoamLogix
The FoamLogix system consists of three main components:
1) Foam Pump / Motor Assembly.
2) Control Panel (integral with main pump control panel).
3) Flow measurement and injection manifold.
All three elements combine to provide accurate foam proportioning. From the control
panel the operator can initiate the system, adjust the foam ratio, monitor ‘real time’
water flow rate and record total water and foam usage.
The FoamLogix system is powered up when the PTO is engaged. Foam agent is only
injected when the RED ON control button is operated.
The Hale FoamLogix foam proportioning system provides consistent foam
concentrate injection for Class A foam operations and is capable of delivering a ratio
of foam typically 0.1% to 10.0%.concentrate directly into the water discharge stream.
Further information is available in the FoamLogix Model 3.3 & 5.0 Description,
Installation and Operation manual, part number 029-0020-68-0.
The following connection points should be considered when installing the WT_C or
WS_C assembly into a vehicle.

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
Oil Filling Points
The unit is supplied without oil and must be filled with the correct quantity and
specification before starting the pump.
Bearing Housing
Gearbox
The pump gearbox filling point depends on the gearbox position in relation to the
pump.
Gearbox in Down Position
Oil filling point
For oil type and capacity refer to
Recommended Lubricants
Oil level check
Bearing housing oil
filling point
For oil type and
capacity refer to
Recommended

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
Gearbox in Horizontal Position, Left or Right of pump
The oil filling point is on the side of the casing (RH gearbox shown) and is
symmetrically opposite for LH gearbox.
The oil level check point is lower on the side. Oil capacity and type as down position
detail.
Oil level
check point
Oil Fill
point

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
Separator Tank/Compressor
Note. Separator must be installed in the vertical position as shown. Pipework from
compressor to oil tank must be arranged so that any oil in the compressor will drain
back to the tank.
Oil Fill Point
Oil level indicator

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
Slacken bolt, rotate
tensioner to achieve
specified deflection
and secure
Compressor Drive Belt
The compressor is driven by a synchronous belt.
The installer must allow for access to adjust the jockey pulley belt tensioner. Tension
the belt to achieve a 6-8mm deflection with a 6kg load applied at mid span, see
diagram below.
6-8 mm

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
Foam Tank Low Level Sensor
The unit is supplied with a connector for a low foam level sensor. The sensor is
supplied with the unit ready for installation (instructions supplied with the sensor).
Note: the low foam level switch must be installed in the tank in the correct
orientation. The switch device has a raised marker on the casing where the wires
enter the device. This marker must be installed at the 12 o clock (top) position for
correct functioning.
The foam tank requires a 23mm hole for secure fitting of the switch device and the
maximum allowable thickness of tank wall material is 4mm.
The centre of the level switch should be located a minimum of 40mm above the foam
outflow to the foam pump.
Additional Installation Points
Foam Tank to Foam Pump
The foam feed line must not at any point be lower that the foam pump; have a 13mm
bore and be fitted with an isolating tap for maintenance purposes. The isolating tap
should be located as close to the tank as possible. A flushing point should be fitted
close to the isolating tap to ensure that the maximum length of hose line can be
flushed out. The flushing line should also be fitted with an isolating valve.
The foam tank must be located above the FoamLogix pump unit, with the feed
line free from excess material, kinks or loops.
The foam tank should be made of plastic or stainless steel, with a volume greater
than the vehicle main tank by a factor of 0.005. Alternatively, a volume of at least 25
litres may be preferred to allow an entire drum of foam agent to be contained.
Note: To ensure correct operation of the FoamLogix pump, all connections must be
secure and pressure tight.
Boss location

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
Plumbing Layout

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©Hale Products Europe. Our policy is one of continuous development. We therefore
reserve the right to amend specifications without notice or obligation.
Note hoses marked * should be capable of withstanding pressures of 10 bars and
temperatures of 110oC
CAFS Manifold
Manifold should be mounted with provision for drainage.
Foam and air injection points identified above.
By-Pass Valve
This valve is adjusted to give the required dry foam flow-rate - typically 100
litres/minute.
To set the required dry foam constituency –
1. Install the system as directed
2. Run the system at normal operating pressure, discharge compressed air foam
through the most restrictive line, typically a hose reel.
3. Set the SmartCAFS ARC control to the full dry position.
4. Open or close the By-pass valve (as shown in photograph above) until the
required dry foam flow rate is achieved.
5. Remove the By-pass valve lever so this setting cannot be changed in operation.
Water flow
Foam Injection
Air Injection
3” Victaulic
connection
(Both ends)
By-pass valve
lever for setting
dry foam
consistency